RMXPRT Guide

Czech Technical University in Prague
Faculty of Electrical Engineering

Department of Power Engineering
&
Department of Electric Drives and Traction
MASTER THESIS
Simulation of a Brushless DC Motor in ANSYS Maxwell 3D
Student: Prathamesh Mukund Dusane
Guide: Ing. Karel Buhr, PhD.
Declaration
I hereby declare that the work Simulation of a BLDC Motor in ANSYS Maxwell 3D is my
own work. This thesis is a presentation of my original research work. Wherever contributions of
others are involved, every effort is made to indicate this clearly, with due reference to the literature,
and acknowledgement of collaborative research and discussions.
Written and Submitted in partial fulfillment of the requirements for the degree of Master of Power
Engineering and Management
The work was done under the esteemed guidance of Professor Ing. Karel Buhr, PhD and Ing. Radek
Fajtl of the Czech Technical University in Prague.
Prathamesh Mukund Dusane

For the Czech Technical University, Prague
Date: 2nd June 2016

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Abstract:
This thesis is about the simulation of a Brush-Less Direct Current Machine in the ANSYS
Maxwell Environment. The machine is selected for a high-performance electric-bike as a motor
over the UNEP (United Nations Environment Program) metropolitan drive cycle. Analytical study
of the forces influencing the machine along with industry references and literature review led to
estimation of rated operating parameters. Four models of a 1,500Watt, 380Rpm, 40Nm & 48Volt
BLDC Motor are designed and simulated in the RMxprt module of Maxwell [24 Slot, 36 Slot, 48
Slot, 72 Slot] The software enabled solving and simulation of magneto-static and transient fields
based on Maxwells equations in 2D & 3D. The solution set of each machine is described and
tabulated in the appendix of this thesis. 2D and 3D analysis reveals inconsistencies in the waveform
of winding currents, induced voltages and losses of 24 Slot and 36 Slot Machines due to an error
in the internal software conversion from 2D to 3D in RMxprt, also the field plots show abnormally
low magnetic field density in stator teeth and high current magnitude in the winding of these two
machines. The 48 Slot and 72 Slot machines had consistent 2D and 3D waveform characteristics
although field overlays show localized hot spots of magnetic field density in the stator sections.
Overall the 72 Slot machine suits best for the given application.
Aim & Objective:

In the 1890s, electric bicycles were described and documented within numerous patents. For
example, in 1895, Ogden Bolton Jr. was granted a patent for a battery-powered bicycle with 6pole brush-and-commutator direct current (DC) hub motor mounted in the rear wheel. There were
no gears and the motor could draw up to 100 amperes (A) from a 10-volt battery. [1]
Still today for much of our world, especially in countries of Asia like China, India, South-Korea,
Japan etc. and European countries like Netherlands, Denmark, Hungary, Germany, France, Spain,
Sweden etc. bicycles have been a major form transportation for the masses because the working
and housing areas in most of these densely populated cities are within walking or cycling distance.
An E-Bike is a bicycle that has an integrated motor for the purpose of propulsion. Brushless DC
Motors are commonly used for propulsion of these bikes nowadays. The Brushless DC Motor
design has tremendous advantages. It combines the long life of the induction motor and linearity
of the permanent magnet motor, plus adds higher speed range capability (productivity), size weight
reduction (compact design), and improved torque capability (precision). [2]
The aim of this thesis is to design and simulate a direct drive outer rotor BLDC Machine as a motor
for a high-power and performance electric bike. ANSYS Maxwell is used for designing and
simulating the machine.
Contents
1. Background of the BLDC Machine .......................................................................................................... 8
2. BLDC Machine literature review............................................................................................................ 10
3. ANSYS Maxwell familiarization ......................................................................................................... 12
3.1. ANSYS RMxprt:.................................................................................................................................. 13
3.1.1. The Machine Selection Window .................................................................................................. 13
3.1.2. The Project Window ..................................................................................................................... 14
3.1.3. The Machine Properties Window ................................................................................................. 14
3.1.5. The Circuit Data Properties Window ........................................................................................... 15
3.1.6 The Stator ...................................................................................................................................... 15
3.1.7. Slot Dimensions:........................................................................................................................... 16
3.1.8. The Stator Winding Properties Window....................................................................................... 16
3.1.9. The End/Insulation Tab ................................................................................................................ 17
3.1.10. The Rotor .................................................................................................................................... 18
3.1.11. The Pole Properties Window ...................................................................................................... 18
3.1.12. The Shaft Data Properties Window ............................................................................................ 19
3.1.13. The Analysis Setup Window shown in Figure 21 ...................................................................... 19
3.1.14. Solution Data: ............................................................................................................................. 19
3.1.14.1. Performance ........................................................................................................................ 19
3.1.14.2. Design Sheet........................................................................................................................ 20
3.1.14.3. Curves.................................................................................................................................. 20
4. 1500 W, BLDC Machine Analytical Model ........................................................................................... 21
4.1. Air Resistance/Aerodynamic Drag: ..................................................................................................... 22
4.2. Rolling Resistance: .............................................................................................................................. 23
4.3. Acceleration Force: .............................................................................................................................. 23
4.4. Total Power: ......................................................................................................................................... 24
4.5. Angular Velocity:................................................................................................................................. 24
4.5. Torque: ................................................................................................................................................. 24
5. 1500W BLDC Outer Rotor Machine Electro-Magnetic Design ............................................................. 25
5.1. 24 Slot, 16 Pole BLDC Machine in ANSYS Maxwell - RMxprt: .................................................... 25
5.1.1. Machine & Circuit: ....................................................................................................................... 25
5.1.2. Stator Dimensions: ....................................................................................................................... 25
5.1.2.1. Slot Design: ........................................................................................................................... 26
5.1.2.2. Winding Design: ................................................................................................................... 26
5.1.3. Rotor Dimensions: ........................................................................................................................ 27

5.1.3.1. Pole Data: .............................................................................................................................. 27
5.1.4. Analysis Setup: ............................................................................................................................. 27
5.1.5. Solution Data: ............................................................................................................................... 28
5.2.1. Machine & Circuit: ....................................................................................................................... 30
5.2.2.1. Slot Design: ........................................................................................................................... 30
5.2.2.2. Winding Design: ................................................................................................................... 31
5.2.3.1. Pole Data: .............................................................................................................................. 32
5.2.4. Analysis Setup: ............................................................................................................................. 32
5.2.5. Solution Data: ............................................................................................................................... 33
5.3.1. Machine & Circuit: ....................................................................................................................... 35
5.3.2.1. Slot Design: ........................................................................................................................... 35
5.3.2.2. Winding Design: ................................................................................................................... 36
5.3.3.1. Pole Data: .............................................................................................................................. 37
5.3.4. Analysis Setup: ............................................................................................................................. 37
5.3.5. Solution Data: ............................................................................................................................... 38
5.4.1. Machine & Circuit: ....................................................................................................................... 40
5.4.2.1. Slot Design: ........................................................................................................................... 40
5.4.2.2. Winding Design: ................................................................................................................... 41
5.4.3.1. Pole Data: .............................................................................................................................. 42
5.4.4. Analysis Setup: ............................................................................................................................. 42
5.4.5. Solution Data: ............................................................................................................................... 43
6. 1500 W, BLDC Machine 2D/3D design in Maxwell RMxprt module: ............................................... 45
6.1. 24 Slot, 16 Pole Machine 2D Model in ANSYS Maxwell -RMxprt: ............................................... 46
6.1.1. Results and Field Overlays: .............................................................................................................. 46

6.2. 36 Slot, 16 Pole Machine 2D Model in ANSYS Maxwell RMxprt: .............................................. 48
6.5. About the Maxwell Mesh..................................................................................................................... 54
6.5.1. Meshing in Maxwell ..................................................................................................................... 54
6.6.1.1: Observations:......................................................................................................................... 57
6.7.1.1: Observations:......................................................................................................................... 61
6.8.1.1: Observations:......................................................................................................................... 65
6.9.1: Results and Field Overlays ........................................................................................................... 66
6.9.1.1: Observations:......................................................................................................................... 69
7. 2D/3D Observations and Result Analysis:.............................................................................................. 70
7.1. 2D & 3D Result Analysis: ................................................................................................................... 72
8. Conclusion: ............................................................................................................................................. 73
9. Bibliography ........................................................................................................................................... 74
Appendix 1: 24 Slot, 16 Pole Machine Solution Set:.................................................................................. 76
Stator Slot ............................................................................................................................................... 76
For Armature Winding: .......................................................................................................................... 79
For Armature Winding: .......................................................................................................................... 95
Appendix 4: 72 Slot, 32 Pole Machine Solution Set:................................................................................ 100
For Armature Winding ......................................................................................................................... 103
Appendix 5: Steel Data: ............................................................................................................................ 108
1. Background of the BLDC Machine

Brushless DC motors are rapidly evolving, thanks to the advancements in solid state
semiconductor technology and further improvements in magnetic materials. A BLDC (Brush-less
direct current) motor, also known as an electronically commutated motor is a type of synchronous
motor powered by a DC source integrated with an inverter or switching power supply, which
converts DC to AC signal to power the motor. Here, AC does not refer to the sinusoidal shape of
the wave, but rather a bi-directional current with no restriction on its waveform. [3]
Just like all other motors a BLDC motor consists of a Stator and a Rotor, permanent magnets are
mounted on the rotor while the stator is usually made by stacking slotted steel laminations wound
with a specific number of poles. The stator can also be slotless, a slotless core has lower inductance,
and thus it can run at very high speeds. [4]
The power convertor is responsible for commutation, which is the act of changing the motor phase
currents at the appropriate times to create a Rotating Magnetic Field (RMF) thereby producing
rotational torque. The RMF is maintained by using the appropriate phase sequence to supply the
stator phases. One pole of energized stator phase attracts one of the rotor poles, while the second
pole of the energized stator phase repels the corresponding pole of the rotor. This action of the
rotor chasing the electromagnet poles on the stator is the fundamental working principle of BLDC
motors.
Based on relative position of the Stator & Rotor, the BLDC motor can be classified as,
1. Inner Rotor/Inrunner The rotor along with its embedded permanent magnets are in the
center of the machines whereas the windings of the stator surround the rotor.
2. Outer Rotor/Ourunner The stator coils form the center (core) of the motor while the
permanent magnets spin within a rotor that surrounds the stator. [5]
Figure 1: Outer Rotor Motor (Left), Inner Rotor Motor (Right) [6]
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The BLDC motors control is based on the information about position of its rotor. The estimation
of rotor position in brushless DC motors can be either sensored or sensorless.
In the case of sensor based control a Hall-effect position sensor I.C. (Integrated Circuit) detects
the position of the rotating magnet in the rotor and excites the corresponding windings through
logic and driver circuitry. The rotating permanent magnet moving across the front of the sensor
causes it to change state. The sensor operates when each South Pole approaches. [7]
In sensorless control the principle used for rotor position estimation and control is to analysis of
the Back-Electromotive Force (BEMF) from the motor. Back-EMF is the voltage induced in the
stator winding of the motor by a rotating magnetized rotor. The magnitude of back-EMF is
proportional to the speed of the motor. [8] A BLDC motor has trapezoidal waveform of backEMF, as opposed to the sinusoidal waveform back-EMF found in permanent magnet synchronous
motor. [9]
There are two types of electrical wiring configurations for the winding,
1. Delta () Configuration The 3 phase winding of the stator are connected to each other in
a series combination resembling a triangle like circuit. Here, 3 terminals are available for
control.
2. Star (Y) Configuration The 3 phase winding of the stator are connected to each other in
a parallel combination to a central point (star point/neutral point). Here, 4 terminals are
available for control.
Based on the form factor of the permanent magnet synchronous machine, the BLDC motor is
classified below in Figure 2, also present are Circumferential and Transverse flux machines.
1. Axial Flux The axial flux motors have a flux that runs parallel to the output shaft, that is,
along the axis of the shaft, thus, axial. These type of machines can be stacked in parallel
making them multi-staged.
2. Radial Flux A radial flux motor has its flux running in and out from the center of the
shaft, on the radius, hence radial.
Figure 2: A) Radial Flux Motor, B) Axial Flux Motor [10]

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2. BLDC Machine literature review

The paper [11] describes design scope and analysis issues about the BLDC machine like selection
of pole number, winding layout, rotor topology, drive strategy, eld weakening and cooling. The
scope of the paper is limited to radial flux motors, the paper discussed some ratings to dimension
the motor, it also differentiated between AC & DC control. The following section sheds light on
the factors determining the pole number of the machine and its importance and characteristics in
the operation of the motor, in this section the authors have also mentioned strategies in slot design
to reduce cogging torque. The authors placed importance on the number of slots & poles along
with the number of coil sides in a slot for choosing the AC winding design, whereas the authors
resolved that a fully pitched concentrated winding is necessary for DC winding design. Then next
section mentions about the selection magnets and their dimensioning for designing the rotor, the
authors pointed out the importance of not operating magnets in their non-linearity zone, they also
laid constraints on the thermal loading of the magnets. The authors also warned about having
impractically high stator slot fill percentages and advised caution. In the next section of the paper
the author has discussed thermal considerations for selecting current density in the winding along
with some popular cooling methods. The last section of the paper shows I-Psi & Efficiency plots
of a PMDC machine to judge it torque and performance, the authors also mentioned effect of phase
angle advance setting of the converter on the efficiency of the machine. Overall, the authors have
presented a comprehensive design analysis of the brushless permanent magnet machine with many
notable references.
In [12], Srivastava and Brahmin describe the design and simulation of a 3-phase double layer coil
BLDC motor (Hub Drive Machine) for Electric Vehicles (EV) using ANSYS software. Two 15
kW brushless BLDC motors are designed, simulated and compared, one has 36 Slots/24 Poles
while the other has 36 Slots/16 Poles. FEM is used by the authors to resolve the electromagnetic
field using Variational Calculus of Poissons type from the basic Magneto-Static Maxwells
equations. The authors have graphically depicted their observations of Torque v/s Rotation Angle
for all three phases. 2D mesh analysis in ANSYS - Maxwell revealed that the rated torque
requirement is achieved from configuration - II (36S/16P). They concluded that with reduced
number of poles high speed of rotation could be achieved easily.
In [5], the authors have aimed to design an optimal outer rotor BLDC motor parameterized for low
cogging torque. They have used ANFOT Maxwell to model the rotor & stator of the motor and
also verify its Pole/Slot combinations. The authors concluded that cogging torque was lowest in
26 Slot motors and was heavily influenced by slot aperture, wider slot openings leading to higher
cogging torque, the authors also suggest that, the number of poles have a significant influence of
the cogging torque of the machine, lower number of poles produced lower cogging torque.
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The paper published by IEEE Transactions in Magnetics [13], the authors have presented an
efficiency study of a 1.5kW 2 & 6 Pole Induction Motor converted to 1.5kW 2 & 6 Pole BLDC
Motor, they have modified the rotor of an induction motor to a PM rotor (NdFeB) and reported a
higher average efficiency of 14% and consequent increase in speed and torque range. Afterwards,
the authors have replaced the stator steel of the IM with M253-35A steel type in the BLDC motor
with the same geometric design and reported a further 2% increase in efficiency.
The journal paper by [14], the author examines the effect of stator slot structure and switching
angle on a cylindrical single-phase brushless direct current motor (BLDC). Three types of default
slot designs are compared in RMxprt of Ansys Maxwell, then the motor is analyzed in Maxwell
3D electromagnetically using FEM, and at the end with the use of MATLAB the author the
examined influence of switching angle on motor performance. The author indicates that with
correct choosing of stator slots & its structure along with switching angle, maximum efficiency
can be attained. His results are, that motors operate better when the windings are switched ON
earlier with respect to the emfs induced in them, which means that if voltage inverters are applied
to the inverters they should operate at an advanced switching angle for maximum efficiency ( =
- 45deg), the default slot structure number 3 of RMxprt was found to have largest flux density and
the smallest inductance leakage.
A paper by James R. Hendershot of the Magna Physics Corporation [15] analyzes the phase , rotor
poles and stator slots such that the best selection can be made before the actual motor design is
attempted, the author has analyzes and compared various phase, pole and slot configurations. It is
shown by the author that with increase in number of phases, the ripple content in the machines
torque decreases although the number of switches & sensors needed for commutation increases
along with the system cost. The author has summarized the effect of number of poles as, higher
the number of poles lower is the motor speed and vice a versa. Considering the number of slots
the author has advised that if a low cost, sinusoidal motor is desired then 3.75 Slots/Pole
configuration is best. The author has then listed numerous Slot/Pole configurations along with the
number of slots & poles respectively. In the final section the author has analyzed the back EMF of
the slot/pole groups using Fourier series on an IBM PCAT computer for star and delta connections.
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3. ANSYS Maxwell familiarization

ANSYS, Inc. is an American Computer-aided engineering software developer headquartered south
of Pittsburgh in Pennsylvania, United States. Ansys publishes engineering analysis software across
a range of disciplines like finite element analysis, structural analysis, computational fluid
dynamics, explicit/implicit methods, and heat transfer.
ANSYS Maxwell is a high-performance, low frequency electromagnetic field simulation
interactive software package that uses finite element analysis (FEA) to solve electromagnetic
problems by solving Maxwell's equations in a finite region of space with appropriate boundary
and user-specified initial conditions for 2D/3D electromagnetic and electromechanical devices,
including motors, actuators, transformers, sensors and coils. Maxwell uses the accurate finite
element method to solve static, frequency-domain, and time-varying electromagnetic and electric
fields. The software can only use a triangular/tetrahedral elements to mesh the domain and linear
interpolation functions to approximate the solution. [16]
The physical equations that describe the electromagnetic field given by James Clerk Maxwell are
[17],
Gauss Law for Electricity . =
Gauss Law for Magnetism . =
Faradays Law of Induction =

Amperes Law = +
E = Electric field
= Charge density
B = Magnetic field
0 = Permittivity
J = current density
D = Electric displacement
0 = Permeability
H = Magnetic field strength
M = Magnetization
P = Polarization
Numerical techniques are necessary to solve equations above, which is the cause of software
simulation.
12
3.1. ANSYS RMxprt:

(RMxprt) Rotating Machine Expert is a template-based design tool of the ANSYS Maxwell suite
used to create a customized machine design flow to meet demand for higher efficiency. Using
classical analytical motor theory and equivalent magnetic circuit methods, RMxprt can calculate
machine performance, make initial sizing decisions and perform numerous "what if" analyses.
RMxprt is able to automatically set up a complete Maxwell project (2-D/3-D) including geometry,
materials and boundary conditions. The set up includes the appropriate symmetries and excitations
with coupling circuit topology for electromagnetic transient analysis. [18] [19]
Figure 3: Machine selection interface in RMxprt
3.1.1. The Machine Selection Window in Figure 3 includes all possible AC & DC rotating
machines within the Maxwell RMxprt mainframe, with each machine having its own predefined
dimensions & mechanical properties.
On selection of any machine a graphical user interface opens on the screen which includes five
windows and four toolbars each having various functions, out of them the most important is the
Project Window.
13
3.1.2. The Project Window in Figure 4 includes a dropdown tool list whose main components
are,
1. Machine
Circuit
Stator
Rotor
Shaft
2. Analysis
3. Optimetrics
4. Results
Figure 4: Project Manager Window

3.1.3. The Machine Properties Window includes general information depicted in Figure 5, the
number of poles has to be an even number integer, the position of the rotor can be either inner or
outer rotor, the frictional & winding (air-resistance) loss along with reference speed are user
defined quantities. The control type can be DC or CCC (Current Chopped Control).
The circuit type can be,
1.
2.
3.
4.
5.
6.
Y3 Y Type, 3
L3 Loop Type, 3
S3 Star type, 3
C2 Cross Type, 2
L4 Loop Type, 4
S4 Star Type, 4
Figure 5: Machine Properties Window
Figure 6: Circuit Properties Window
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3.1.5. The Circuit Data Properties Window depicted in Figure 6 defines excitation circuit data
for a BLDC machine, the Lead Angle of Trigger is illustrated in Figure 7, and the graph shows
open circuit induced voltage v/s rotor position in electrical degrees. An angle of zero means that
induced voltage in the triggered phase is maximum. A positive value denoted a lead angle while
a negative value is a lag angle. The Trigger Pulse Width is the on-time of a transistor in electrical
degrees. The Transistor drop defines the voltage drop across one transistor in the ON state. The
Diode Drop is to quantify the voltage drop across a diode in the discharge loop.
Figure 7: Lead Angle of Trigger [19]

3.1.6 The Stator is a slotted lamination stack where poly-phase windings reside, the Stator Entry
option is shown in Figure 8. The Outer & Inner Diameters along with Length and Slot Number
are user defined inputs and change with the type of motor modelled. Stacking factor is to quantify
the total stator steel area to the area covered by lamination varnish. Various types of steel can be
described by the software, also steel types can be added and modelled if their parameters are known
is known along with coefficients of core loss Ke, Kc, Kh. There are six types of slots provided in
RMxprt for rotating machines. Skew Width quantifies the skew angle of a slot defined as in slot
width unit.
Figure 8: Stator Properties Window
15
3.1.7. Slot Dimensions: the Stator option in RMxprt for BLDC motors includes slot properties
and Winding Properties, the possible slot dimensions are depicted in Figure 9, while a slot model
is depicted in Figure 10.
Figure 9: Slot Dimensions Window
Figure 10: Slot Model
3.1.8. The Stator Winding Properties Window is shown in Figure 11 lists the inputs relating to
the winding of the machine, the number maximum winding layers can be two, the type of winding
can user defined in an editor along with Whole-Coiled or Half-Coiled winding shown in Figure
12. Six windings are possible three for single layer and three for double layer.
Figure 12: Whole Coiled (Left) & Half Coiled (Right)
Figure 11: Winding Properties Window

The number of Parallel Branches in one phase of the winding is specified in the Parallel Branches
field of the Winding Properties Window. The number of Conductors per Slot is the value of
number of turns per coil multiplied by number of layers.
16
The Coil Pitch is number of slots separating one winding, for example, if a coil starts in slot 1 and
ends in slot 6, its coil pitch is 5. Number of Strands defines the number of wires per conductor.
Wire Wrap is the double sided thickness (2Y) of insulation on a conductor illustrated in Figure 13.
The Wire Size includes the wire diameter in a pull down list along with an appropriate wire gauge.
Y
Conductor
Insulation
Figure 13: Wire Wrap of a Conductor
Figure 14: End/Insulation Tab
3.1.9. The End/Insulation Tab shown in Figure 14 is for the dimensioning of Coil Ends and Slot
Insulation, illustrated in Figure 15 & Figure 16 respectively. The End Extension is the distance
between the end of stator and one end of a conductor. The Base Inner Radius is the radius of the
base inner corner, while the Tip Inner Diameter is the inner diameter of the coil tip. End Clearance
is the distance between two stator coils. Slot Liner is the measure of thickness of the slot liner
insulation, while Wedge Thickness is the measure of thickness of the wedge insulation in the stator
slot. Layer Insulation is the thickness of the insulation layer. Limited Fill Factor is the ratio
between cross-sectional areas of all conductors in one slot to the whole area of the slot.
Figure 15: Coil End of the Winding [19]
Figure 16: Slot Insulation of the Stator [19]

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3.1.10. The Rotor of a BLDC machine is a stack of laminated steel stampings with permanent
magnets on the periphery or embedded inside. The magnetic field of the stator coils react to the
field of the rotor thereby resulting in a force causing rotary motion. The Rotor Data Properties
Window is depicted in Figure 17. The general properties like Outer & Inner Diameter along with
Length are user defined fields. The software describes various Steel Types and also has the option
for user defined additions. The Stacking Factor is the measure of ratio of cross sectional area of all
laminations to the area of steel which is varnish insulated. RMxprt supports five types of Pole
Models, some of the Rotor Data Fields change or get inactive depending on the type of pole
selected.
Figure 17: Rotor Data Properties Window
3.1.11. The Pole Properties Window is depicted in Figure 18. Embrace is defined as the ratio of
actual pole arc distance to the maximum possible arc distance, the value is between 0 & 1 and is
illustrated in Figure 19. Offset is the pole arc center offset from the rotor center (0 for uniform air
gap). RMxprt describes many types of magnetic materials and has the option of adding new
materials. Magnet Thickness field describes the maximum thickness of the magnet for all pole
types.
Pole Embrace = 1
Figure 18: Pole Properties Window
Pole Embrace = 0.8
Figure 19: Pole Embrace

18
3.1.12. The Shaft Data Properties Window of the BLDC machine is depicted in Figure 20. The
only input filed here is the Magnetic Shaft Checkbox which enable the shaft of the machine to be
made of magnetic material.
Figure 20: Shaft Properties Window

3.1.13. The Analysis Setup Window shown in Figure 21 of the BLDC Motor in RMxprt is used
to define the rated input/output parameters of the motor. The Operation Type is Motor in this case.
The Load Type can be,
1. Constant Speed Speed of the motor is constant
2. Constant Power Output power of motor is constant
3. Constant Torque Torque remains constant regardless of speed
(TLOAD = TRATED = POUT/NRPM).
4. Linear Torque Torque increases linearly with speed (TLOAD = TRATED * NRPM/NRATED)
5. Fan Load The load varies non-linearly with speed (TLOAD = TRATED * (NRPM/NRATED)^2)
The Rated Output Power field describes the power developed at the shaft of the motor. The Rated
Voltage field represents the RMS line-to-line voltage. Rated Speed defines the output speed of the
motor at which measurements are recorded. Operating Temperature, as the name suggests is for
quantifying the functional temperature of the motor.
Figure 21: Analysis Setup Window

3.1.14. Solution Data: RMxprt is now ready & eligible to analyze the machine, the Solution Data
is divided into three tabs Performance, Design Sheet and Curves, which are expanded in the
following section
3.1.14.1. Performance - This contains a Data field with a drop-down menu (Figure 22) that allows
you to view many different data tables, which vary with the machine type.
19

Aux Winding Full Load Operation Material Consumption No Load Operation Permanent
Magnet Rotor Data Rated Parameters Stator Slot Stator Winding Steady State Parameters
3.1.14.2. Design Sheet - The file contains tables with information of the performance (Figure 23)
depending on the machine type.
General Data Stator Data Rotor Data Permanent Magnet Data Material Consumption
Rated Operation No-Load Operation Steady State Parameters No Load Magnetic Data Full
Load Data Winding Arrangement Transient FEA Input Data
3.1.14.3. Curves - This displays the plots that were automatically generated by the solver
(Figure 24).
Input DC Current vs Speed Efficiency vs Speed Output Power vs Speed Output Torque vs
Speed Cogging Torque in Two Teeth Induced Coil Voltage at Rated Speed Air Gap Flux
Density Induced Winding Phase Voltage at Rated Speed Winding Currents under Load Phase
Voltage under Load
Figure 22: Efficiency v/s Speed
Figure 22: Stator Winding Performance
Figure 23: Full-Load data Design Sheet
20
4. 1500 W, BLDC Machine Analytical Model

The machine is selected for the application of a high - power electric - bike. The first step in order
to design the machine is to establish the objectives of the work according to the energy
consumption and the performance of the vehicle for individual use.
The amount of power a vehicle needs in order to travel at a given speed can be approximately
calculated by adding the resistances (Forces) it has to overcome. Three types of road resistances
have to be taken into account. [20] [21]
1. Passive vehicle resistances
2. Resistances for overcoming the inertial forces of moving masses
3. Resistances given by the profile of the track
For dimensioning of the system, the inputs are as follows, the e-bike is assumed to travel at
40Km/Hr. (11.11m/s) at 0 slope. Tabulated below (Table 1) are the approximate weights of the
system.
Component
Weight (Kg)
Bicycle
20
Motor & Transmission
12
Control & Electronics
3
Battery
12
Cyclist
80
Total (m)
127 to 130
Table 1: System component weights
The resistances which must be considered for the dimensioning of the system are,
1.
2.
3.
4.
FA - Air resistance/Aerodynamic drag

FR - Rolling resistance
FG - Climbing resistance/Gravity Force Component
FM - Acceleration force
1. Air Resistance/Aerodynamic Drag
FA = C S 2 [3.6 2]
(1)
2. Rolling Resistance
FR = cos
(2)
3. Climbing Resistance
FG = sin
(3)
4. Acceleration Force
FM =
21
(4)
Where,
F Force (N)
C Coefficient of air-resistance/Nose form factor
S Cross-Sectional Windward Area (m2)
Air Density (Kg/m2)
VR Velocity of the bike relative to the wind velocity (Km/Hr.)
f Coefficient of rolling-resistance
m Mass of the whole bike (Kg)
g Gravitational Constant (m/s2)
Slope angle/Climbing Angle ()
V Velocity of the bike (m/s)
4.1. Air Resistance/Aerodynamic Drag:

The motor must provide power to overcome the resistance provided by air. This power is
influenced by the nose form factor (C) of the vehicle and its cross-sectional area (S).
Air density depends on the temperature and on atmospheric pressure. In European conditions,
where the ambient temperature & pressure conditions vary from -25C to +40C and the pressure
varies from 98.5 103.5 kPa, air density can be taken as 1.326 Kg/m2. Typical values of the
nose form factor/coefficient of aerodynamic drag are tabulated below [20].
Vehicle Type
Nose form factor
One-track (bicycle/motor-cycle)
Passenger vehicle
0.6
- 1.2
0.25 - 0.4
Open passenger vehicle
0.5
- 0.65
Van
0.4 - 0.5
Motor-truck
0.8 - 1.0
Table 2: Nose Form Factor of Vehicle
The force to overcome aerodynamic drag can be calculated from equation (1) as:
(...)
(..)= 24.55N
1W is the power required by an object of 1Kg to accelerate at 1m/s2 through a distance of 1m in 1

second. W = Nm/s, therefore, the total watts needed are = . . = 272.75W.
22
4.2. Rolling Resistance:

The force required to overcome the resistance provided by grading of the track, is a function of the
slope & the normal component of the gravity force. For an e-bike traveling on a standard asphalt
road on radial tyre the coefficient of rolling resistance is selected as f = 0.0112. Some values for
the coefficient of rolling resistance for different vehicles and road type are tabulated below. [20]
Wheel Type
Road Type
Rolling-Resistance Coefficcient
[N.kN-1][10-2]
Asphalt track
Passenger vehicle
Diagonal tyre
Radial tyre
Asphalt track
Motor-truck
Diagonal tyre
Radial tyre
Terrain
Motor-truck
Motor-truck / tractor Ploughed Terrain
Rail
Rail vehicle
15
12
- 22
- 18
10 - 15
8
- 12
150 - 200
250 - 500
0.3 - 1
Table 3: Coefficients of Rolling Resistance

The force to overcome the rolling resistance can be calculated from equation (2) as,
= . . = 14.28N,
which in Watts is = . . = 158.68W.
4.3. Acceleration Force:

The reference acceleration of the vehicle can be calculated from the European drive cycle (ExtraUrban) shown below in the (Figure 24).
Figure 24: ECE+EUDC test cycle - also known as the MVEG-A cycle [22]
Hence, the acceleration can be calculated as =
23
()
()()
= 0.694 m/s2
The acceleration force is then calculated from equation (4) as

= = . = 90.22N, which when multiplied by the e-bike speed in m/s
gives us the total acceleration power = . . = 1002.34W.
4.4. Total Power:

The total power to keep the e-bike at 40Km/Hr. is given as the summation of resistances (W)
which the motor has to overcome & is to be taken as the nominal power of the machine.
= + + = + + =
Hence, the total rated output power of the motor is selected as 1500W.
4.5. Angular Velocity:

The angular velocity of the e-bike with a 700c/29er wheel at 40Km/Hr., is the analytical rated
Rpm of the motor & can be calculated as,
= .
(/)
.
= .
= .
()
.
4.5. Torque:
The torque produced by the machine is a function of the angular velocity of the wheel and the
output power of the motor which is expressed as follows,
() =
()
=
= .
. ()
( )
24
5. 1500W BLDC Outer Rotor Machine Electro-Magnetic Design

The above analytical (4) model will now be designed in accordance with the calculated rated
input/output parameters the RMxprt module of ANSYS Maxwell. For this purpose four variants
of the 1500W, BLDC motor are designed and simulated in the software interface.
1.
2.
3.
4.
24 Slots, 16 Pole BLDC machine

5.1. 24 Slot, 16 Pole BLDC Machine in ANSYS Maxwell - RMxprt:

A 24 Slot, 16 Pole machine configuration is selected based on the optimum phase/pole/slot
configurations mentioned in [15]. Its dimensioning will be discussed in the following sections.
5.1.1. Machine & Circuit:
The general machine and circuit parameters are as follows,
Parameter
Value Unit
Number of Poles
16
Frictional Loss
10
W
Windage Loss
20
W
Reference Speed
380 Rpm
Lead angle of trigger
0
Trigger Pulse Width

120
Transistor/Diode Drop
2
V
Table 4: General Machine & Circuit data
The friction and windage losses account to approximately 2% of the total out power capacity.
The transistor and diode drop are usually neglected for power converter dimensioning but here
their value impacts the efficiency significantly.
It is calculated as, = 0.6 + [ ( + )]
5.1.2. Stator Dimensions:
Table 5: Stator Data
Parameter
Outer Diameter
Inner Diameter
Stacking Factor
Length
Steel Type
Number of Slots
Slot Type
Skew Width
Value
Unit
180
mm
90
mm
0.95
50
mm
M100-23P
24
4
1
Slots
25
5.1.2.1. Slot Design:

The selected slot type 4 in RMxprt is based on the research done by [14]. Its design are dimensions
are depicted and tabulated below.
Figure 25: Slot Design (Type 4)

Parameter
Value Unit
End Extension
4
mm
Base Inner Radius
0.5
mm
Tip Inner Diameter
1
mm
End Clearance
1
mm
Slot Liner
0.5
mm
Wedge Thickness
0.3
mm
Layer Insulation
0.1
mm
Limited Fill Factor 0.75
Parameter Value Unit

Hs0
3
mm
Hs1
3
mm
Hs2
30
mm
Bs0
3
mm
Bs1
16
mm
Bs2
8
mm
Rs
0.6
mm
Table 6: Slot Dimensions
Table 7: End/Insulation Data

5.1.2.2. Winding Design:
The stator winding data & geometry is depicted and tabulated below, while the end/insulation data
is depicted above the aim of the design is to minimize the armature copper losses while keeping
the stator slot fill factor in practical limits.
Parameter
Value
Unit
Winding Layers
2
Winding Type
Whole Coiled
Parallel Branches
1
Conductors per slots
18
Coil Pitch
1
Number of Strands
5
Wire Wrap
0.2
mm
Wire Size
1.369
mm
(Diameter)
Table 8: Winding Data
Figure 26: Stator Winding
26
5.1.3. Rotor Dimensions:

The general data for the machine rotor is tabulated below,
Parameter
Outer Diameter
Inner Diameter
Stacking Factor
Length
Steel Type
Pole Type
Value
200
182
0.95
50
M100-23P
1
Unit
mm
mm
mm
Table 9: General Rotor Data

Due to the outer rotor geometry of the BLDC machine only pole type 1 is allowed for analysis
depicted below in Figure 27.
Pole Type 1
Figure 27: Pole Shape 1 in ANSYS Maxwell RMxprt.
5.1.3.1. Pole Data:
The pole data is tabulated below,
Parameter
Value Unit
Embrace
0.9
Offset
4
mm
Magnet Type
NdFeB
Magnet Thickness
4
mm
Table 10: Pole Data
5.1.4. Analysis Setup:
The machines rated operating state input/output parameters are tabulated below,
Parameter
Value
Unit
Load Type
Constant Power
Rated Output Power
1500
W
Rated Voltage
48
V
Rated Speed
380
Rpm
Operating Temperature
75
C
Table 11: Analysis Setup
27
5.1.5. Solution Data:

RMxprt provides an entire range of data types and variables, some important output parameters
and plots are described below.
Parameter
Value
Unit
Armature Current (RMS)
36.23
A
Total Loss
324.78
W
Output Power
1500.2
W
Input Power
1825
W
Efficiency
82.20
%
Rated Speed
359
Rpm
Rated Torque
39.92
Nm
Total Net Weight
7.30
Kg
Total Steel Consumption
15.3
Kg
No-Load Speed
465.25 Rpm
Residual Flux Density(Rotor) 1.23
T
Minimum Air-Gap
1
mm
Stator Slot Fill Factor
60.32
%
Stator Winding Factor
0.86
Single Phase Resistance
0.030
Time Constant
0.005
s
Back EMF Constant (KE)
0.908 V/rad
Rated Torque Constant
1.06
Nm/A
Armature Current Density
4.92 A/mm2
Locked Rotor Torque
665
Nm
Locked Rotor Current
732
A
Stator Teeth Flux Density
3.95
T
Table 12: Solution Data of 24 Slot, 16 Pole, 1500W Motor
Figure 28: 24 Slot, 16 Pole BLDC Motor Cross - Section

28
Figure 29: Efficiency (%) V/s Speed (Rpm)
Figure 30: Output Power (W) V/s Speed (Rpm)
Figure 31: Input DC Current (A) V/s Speed (Rpm)
29

The text below describes the RMxprt design of a 36 Slot, 18 Pole based on configuration
described in [15].
Parameter
Value Unit
Number of Poles
16
Frictional Loss
10
W
Windage Loss
20
W
Reference Speed
380 Rpm
0
Trigger Pulse Width

120
2
V
Circuit Type
Y3
Delta connection is not recommended in a brushless PM machine. If there is any third time
harmonic in the phase back EMF, then this will induce a circulating zero- order current. This will
cause excessive current and copper losses and potential burnout of the winding. [9]
The general data for the stator is tabulated below.
Parameter
Value
Unit
Outer Diameter
220
mm
Inner Diameter
130
mm
Stacking Factor
0.95
Length
50
mm
Steel Type
M100-23P
Number of Slots
36
Slot Type
4
Skew Width
1
Slots
Table 14: General Stator Data
30

Hs0
3
mm
Hs1
3
mm
Hs2
30
mm
Bs0
3
mm
Bs1
13
mm
Bs2
8
mm
Rs
0.6
mm
The stator winding data and geometry along with its end terminations and insulations is depicted
and tabulated below, the aim of the design is to minimize the armature copper losses while keeping
the stator slot fill factor in practical limits.
Parameter
Value
Unit
Winding Layers
2
Winding Type
Whole Coiled
Parallel Branches
1
12
Coil Pitch
1
Number of Strands
6
Wire Wrap
0.2
mm
Wire Size
1.369
mm
(Diameter)
Parameter
Value Unit
End Extension
4
mm
Base Inner Radius
0.5
mm
Tip Inner Diameter
1
mm
End Clearance
1
mm
Slot Liner
0.5
mm
Wedge Thickness
0.3
mm
Layer Insulation
0.1
mm

31

Parameter
Outer Diameter
Inner Diameter
Stacking Factor
Length
Steel Type
Pole Type
Value
240
222
0.95
50
M100-23P
1
Unit
mm
mm
mm

Due to the outer rotor geometry of the BLDC machine only pole type 1 is allowed for analysis.
5.2.3.1. Pole Data:

Parameter
Value Unit
Embrace
0.9
Offset
4
mm
Magnet Type
NdFeB
Magnet Thickness
4
mm
Table 19: Pole Data
Parameter
Value
Unit
Load Type
Constant Power
Rated Output Power
1500
W
Rated Voltage
48
V
Rated Speed
380
Rpm
75
C
32

The important output parameters and plots are described below.
Parameter
Value
Unit
32.67
A
Total Loss
274.93
W
Output Power
1500.22
W
Input Power
1775.21
W
Efficiency
84.50
%
Rated Speed
408.38
Rpm
Rated Torque
35.07
Nm
Total Net Weight
9.23
Kg
22.1
Kg
No-Load Speed
473.53
Rpm
Residual Flux Density(Rotor)
1.23
T
Minimum Air-Gap
1
mm
61
%
0.61
0.025
Time Constant
0.0038
s
0.892
V/rad
0.971
Nm/A
3.7
A/mm2
Locked Rotor Torque
798
Nm
894
A
3.80
T
Table 21: Solution Data of 36 Slot, 16 Pole, 1500W Motor
Figure 34: 36 Slot, 16 Pole, Motor Cross - Section

33

34

The text below describes the RMxprt design of a 48 Slot, 22 Pole with the aim to maximize
performance at rated parameters. [15].
Parameter
Value Unit
Number of Poles
22
Frictional Loss
10
W
Windage Loss
20
W
Reference Speed
380 Rpm
0
Trigger Pulse Width

120
2
V
Circuit Type
Y3
Parameter
Value
Unit
Outer Diameter
240
mm
Inner Diameter
140
mm
Stacking Factor
0.95
Length
50
mm
Steel Type
M100-23P
Number of Slots
48
Slot Type
4
Skew Width
1
Slots
35

Hs0
2
mm
Hs1
2
mm
Hs2
30
mm
Bs0
3
mm
Bs1
10
mm
Bs2
6
mm
Rs
0.5
mm
and tabulated below, the coil pitch is kept minimum to reduce eddy current losses and end
extensions.
Parameter
Value
Unit
Winding Layers
2
Winding Type
Whole Coiled
Parallel Branches
1
9
Coil Pitch
1
Number of Strands
6
Wire Wrap
0.2
mm
Wire Size
1.369
mm
(Diameter)
Parameter
Value Unit
End Extension
5
mm
Base Inner Radius
1.2
mm
Tip Inner Diameter
2
mm
End Clearance
2
mm
Slot Liner
0.7
mm
Wedge Thickness
0.3
mm
Layer Insulation
0.1
mm

36

Parameter
Outer Diameter
Inner Diameter
Stacking Factor
Length
Steel Type
Pole Type
Value
262
242
0.95
50
M100-23P
1
Unit
mm
mm
mm

5.3.3.1. Pole Data:

Parameter
Value Unit
Embrace
0.9
Offset
4
mm
Magnet Type
NdFeB
Magnet Thickness
4
mm
Table 27: Pole Data
Parameter
Value
Unit
Load Type
Constant Power
Rated Output Power
1500
W
Rated Voltage
48
V
Rated Speed
380
Rpm
75
C
37

Parameter
Value
Unit
32.22
A
Total Loss
265
W
Output Power
1500
W
Input Power
1765
W
Efficiency
84.98
%
Rated Speed
378.86 Rpm
Rated Torque
37.81
Nm
Total Net Weight
11.57
Kg
25.2
Kg
No-Load Speed
434.64 Rpm
T
Minimum Air-Gap
1
mm
68.72
%
0.63
0.025
Time Constant
0.0022
s
0.97
V/rad
1.04
Nm/A
3.64 A/mm2
Locked Rotor Torque
864.32 Nm
888.61
A
3.1
T
Table 29: Solution Data of 48 Slot, 22 Pole, 1500 W Motor
Figure 40: 48 Slot, 22 Pole Motor Cross - Section

38

39

The text below describes the RMxprt dimensions of a 72 Slot, 32 Pole with the aim to maximize
performance at rated parameters. [15].
Parameter
Value Unit
Number of Poles
32
Frictional Loss
10
W
Windage Loss
20
W
Reference Speed
380 Rpm
0
Trigger Pulse Width

120
2
V
Circuit Type
Y3
Parameter
Value
Unit
Outer Diameter
270
mm
Inner Diameter
180
mm
Stacking Factor
0.95
Length
47
mm
Steel Type
M100-23P
Number of Slots
72
Slot Type
4
Skew Width
1
Slots
The selected slot type 4 in RMxprt is based on the research done by [14]. The design is based on
the commercial products out in the market during recent times which are depicted and tabulated
below.
40

Hs0
2.5
mm
Hs1
1
mm
Hs2
30
mm
Bs0
3
mm
Bs1
8
mm
Bs2
5.3
mm
Rs
0.5
mm
and tabulated below, the coil pitch is kept minimum to reduce the eddy current losses & end
extensions
Parameter
Value
Unit
Winding Layers
2
Winding Type
Whole Coiled
Parallel Branches
1
6
Coil Pitch
1
Number of Strands
6
Wire Wrap
0.2
mm
Wire Size
1.369
mm
(Diameter)
Parameter
Value Unit
End Extension
3
mm
Base Inner Radius
0.5
mm
Tip Inner Diameter
1
mm
End Clearance
1.1
mm
Slot Liner
0.5
mm
Wedge Thickness
0.2
mm
Layer Insulation
0.1
mm

41

Parameter
Outer Diameter
Inner Diameter
Stacking Factor
Length
Steel Type
Pole Type
Value
290
272
0.95
47
M100-23P
1
Unit
mm
mm
mm

5.4.3.1. Pole Data:

Parameter
Value Unit
Embrace
0.9
Offset
0
mm
Magnet Type
NdFeB
Magnet Thickness
4
mm
Table 36: Pole Data
Parameter
Value
Unit
Load Type
Constant Power
Rated Output Power
1500
W
Rated Voltage
48
V
Rated Speed
380
Rpm
75
C
42

Parameter
Value
Unit
31.57
A
Total Loss
248.33
W
Output Power
1500
W
Input Power
1748
W
Efficiency
85.79
%
Rated Speed
376
Rpm
Rated Torque
38.10
Nm
Total Net Weight
10.40
Kg
31.1
Kg
No-Load Speed
422.83 Rpm
T
Minimum Air-Gap
1
mm
53.92
%
0.61
0.021
Time Constant
0.0012
s
1
V/rad
1.06
Nm/A
3.57 A/mm2
Locked Rotor Torque
1024
Nm
1024
A
3.43
T
Table 38: Solution Data of 72 Slot, 32 Pole, 1500 W Motor
Figure 46: 72 Slot, 32 Pole Motor Cross Section
43
44
6. 1500 W, BLDC Machine 2D/3D design in Maxwell RMxprt

module:
The analyzed model of RMxprt can now be exported to create Maxwell 2D/3D models that include
FE mesh modeling algorithms to solve the machines Magneto Static and Transient equations
along with an external electronic circuit editor called Simplorer, to integrate the machine & the
power convertor, which decides its excitation and there by operating performance.
Shown below (Figure 50) is the external excitation circuit which is modelled automatically in the
software and is used for magneto static and transient analysis. The solid state diodes and switches
are considered by a modelling window where the user can input data like contact resistance,
emission coefficient, barrier height, reverse breakdown voltage and current. The switch model
includes variable inputs like on/off state resistance and control voltages.
Model
DModel1
D40
D42
S_48
D35
SModel1
D44
V
S_46
Model
V
D37
S_50
D39
LabelID=V32
24V
LabelID=VIA
3.30093e-006H*Kle
0.0316931ohm
LA
RA
3.30093e-006H*Kle
0.0316931ohm
LB
RB
3.30093e-006H*Kle
0.0316931ohm
LC
RC
LPhaseA
LabelID=VIB
+
-
LPhaseB
LabelID=VIC
LabelID=V33
24V
D41
D43
D45
S_47
D36
S_49
D34
LPhaseC
D38
S_51
LabelID=IVc1
LabelID=IVc2
LabelID=IVc3
LabelID=IVc4
LabelID=IVc5
LabelID=IVc6
100ohm
100ohm
100ohm
100ohm
100ohm
100ohm
R20
R21
LabelID=V14 +
1V
-1
R22
LabelID=V15 +
1V
-1
R23
LabelID=V16 +
1V
-1
R24
LabelID=V17 +
1V
-1
R25
LabelID=V18 +
1V
-1
LabelID=V19
1V
-1
Figure 50: ANSYS Simplorer Excitation Circuit

The eddy current effects were neglected in the above excitation scheme due to single coil pitch
winding.
45
6.1. 24 Slot, 16 Pole Machine 2D Model in ANSYS Maxwell RMxprt:

Depicted below is the 2D model along with its FE mesh plot of the machine, the grey sections are
Electric Steel, the green sections are Permanent Magnets, while the golden ones are copper
conductors.
Figure 51: 2D Machine Cross - Section
Figure 52: 2D Mesh Plot
6.1.1. Results and Field Overlays:

Before analyzing the 2D design it is important to apply and plot mesh operations along with
integration of external excitation circuit. Shown below are the plots for Moving Torque and
Winding Currents v/s time.
Figure 53: Moving Torque (Nm) V/s Time (ms)

46
Figure 54: Winding Currents (A) V/s Time (ms).
Figure 55: Electric Current Density (A/m2)
Figure 56: Magnetic Field Strength (T)
Figure 57: Flux Lines (Wb/m)
Figure 58: Magnetic Field Strength (A/m)

47
6.2. 36 Slot, 16 Pole Machine 2D Model in ANSYS Maxwell

RMxprt:
Electric Steel, the green sections are Permanent Magnets, while the golden ones are copper
conductors.
Figure 59: 2D Machine Cross - Section

Shown below are the plots for Moving Torque and Winding Currents v/s time.
48
Figure 62: Winding Currents (A) V/s Time (ms)

49

RMxprt:
Electrical Steel, the green sections are Permanent Magnets, while the golden ones are copper
conductors.
Figure 67: 2D Machine Cross Section

50

51

RMxprt:
Electrical Steel, the green sections are Permanent Magnets, while the golden ones are copper
conductors.
Figure 75: 2D Machine Cross Section


52

53
6.5. About the Maxwell Mesh

Maxwell uses the Finite Element Method (FEM) to solve Maxwells electro-magnetic field
equations. In order to obtain the set of algebraic equations to be solved, the geometry of the
problem is discretized automatically into basic platonic solids (e.g. Triangle in 2D & Tetrahedron
in 3D). The assembly of all tetrahedra/triangles is referred to as the finite element mesh of the
model or simply, the mesh. [23]
Figure 83: 2D FEM element Triangle
Figure 84: 3D FEM element Tetrahedron
Mesh plays important role in accuracy of the computed results and thus a higher mesh resolution
is required in regions where fields intersect rapidly.
6.5.1. Meshing in Maxwell
Maxwell meshes all solids (model Objects) in the geometry automatically before solution process
is started. In Maxwells Static Solvers, the mesh is automatically refined to achieve the required
level of accuracy in field computation. This is referred as Adaptive mesh refinement Maxwell also
offers wide range of mesh operations which can be utilized to achieve a mesh as required by users
54

RMxprt:
Depicted below is the 3D model of the machine along with its FE mesh plot & magnetic field
density plot, the grey sections are Electrical Steel, the green sections are Permanent Magnets, while
the golden ones are copper conductors.
Figure 85: 3D Machine Section
Figure 86: 3D Mesh Model

Shown below are the plots for Moving Torque and Winding Currents v/s time along with field
overlays (T).

55
Figure 89a: Magnetic Field Strength (T)

56
Figure 89b: Magnetic Field Strength (X-Y) (T) Plane

6.6.1.1: Observations:
Results show the torque pulsating between 10 15 Nm every 8 ms. Winding currents have peaks
and harmonics which can be attributed to the torque pulsations, although the winding currents
have abnormally high magnitude. Field Overlays of the Magnetic field show a magnitude of 1.3
T in isolated regions of the permanent magnet inner face which is the nominal expected value,
while the stator tooth field density barely reaches 0.8 T, this is an abnormally low value and can
be attributed to the input of inaccurate electric steel selection in the RMxprt module.
57

RMxprt:

Shown below are the plots for Moving Torque and Winding Currents v/s time along with field
overlays (T).

58
Figure 94: Magnetic Field Strength (X-Y Plane) (T)

59
Figure 95a: Magnetic Field Strength (T)
60
Figure 96b: Magnetic Field Strength (Streamlined Vector) (T) Plane

Results show the torque pulsating between 10 17.5 Nm every 3 ms. Winding currents have
plateaus and minor dips which can be attributed to the torque pulsations, although the winding
currents have abnormally high magnitude. Field Overlays of the Magnetic field shows the nominal
expected value, while the stator tooth field density barely reaches 0.8 T, this is an abnormally low
value and can be due to the input of inaccurate electric steel selection in the RMxprt module.
61

RMxprt:

Shown below are the plots for Moving Torque and Winding Currents v/s time along with Field
Overlays (T).

62
Figure 101a: Magnetic Field Strength (X-Y Plane) (T)
63
Figure 101b: Magnetic Field Strength (T)
64
Figure 101c: Magnetic Field Strength (Streamlined Vector) (T)
The moving torque is oscillation between 40Nm to 25Nm every 2 ms, with the magnitude of the
torque same as the rated torque. The magnitude of winding currents is at an average value of 36A,
which is its nominal rated value. There is approximately, an oscillation in current with a magnitude
of 10A at high frequency, it is deduced that it may be due to torque pulsations. Magnetic Field
plots show a density magnitude of 3T and excess in the stator teeth, which is relatively high for
typical electrical steels and a machine of this size and rating. The strength of the magnet is at its
nominal value of 1.3T. Streamlines show localized spots on the stator with a peak field density of
4 T. These abnormally high value can be attributed to the inaccurate core model of the machine.
65

RMxprt:
6.9.1: Results and Field Overlays

Shown below are the plots for Moving Torque and Winding Currents v/s time along with magnetic
field density overlays.
66
Figure 106a: Magnetic Field Strength (X-Y Plane) (T)
67
Figure 106b: Magnetic Field Strength (T)
68
Figur1e 106c: Magnetic Field Strength (Streamlined Vector) (T)
The moving torque is pulsating between 43 Nm to 30 Nm every 2 ms, the characteristic has sharp
peaks and dips which reflect itself in the winding currents waveform, the winding current has sharp
pulsation in each half cycle with an approximate magnitude of 18 A over a period of 1.2 ms with
a period of 10 ms. Magnetic field density plots show a magnitude of 3 T and excess in some of the
stator teeth, this value is at the operating limit of the magnetic field density in the electrical steel.
It is interesting to note that the field density exactly in the central section of the rotor core behind
the permanent magnet is very low compared to the side sections, this is the case with all the models.
69
7. 2D/3D Observations and Result Analysis:

Tabulated below are the observations from the 2D and 3D plots and field overlays.
Machine
24 Slot, 16 Pole
36 Slot, 16 Pole
2D Model
9959 Triangular Units
Moving Torque:
1. Rise Time: 11.21 ms
2. Value: 10.30 Nm
3. Pulsation: 8.4 Nm,
3.40 ms
4. Crest Factor: 1.66
5. Ripple: 43.97
Winding Currents:
1. RMS: 4.2 A
4. di/dt: 2.05 A/s
Induced Voltages:
1. RMS: 19.1 V
2. Distortion: 23
3. Frequency: 48.7 Hz
Stranded Losses:
1. Average: 2.85 W
2. Maximum: 4.91 W
Flux Linkages:
1. RMS: 0.0296 Wb
Moving Torque:
2. Value: 20.67 Nm
2.6 ms
5. Ripple: 24.29
Winding Currents:
1. RMS: 13.55 A
4. di/dt: 2.86 A/s
Induced Voltages:
1. RMS: 20 V
2. Distortion: 90
70
3D Model
47655 Tetrahedra
Moving Torque:
2. Value: 13.89 Nm
1.79 ms
5. Ripple: 14.30
Winding Currents:
1. RMS = 272 A
4. di/dt: 54.83 A/s
Induced Voltages:
1. RMS: 7.5 V
2. Distortion: 9000
4. Crest Factor: 4
Stranded Losses:
1. Average: 20.64 kW
2. Maximum: 34.53 kW
Flux Linkages:
1. RMS: 0.0273 Wb
116700 Tetrahedra
Moving Torque:
2. Value: 17.21 Nm
3. Pulsation: 6.5 Nm, 2
ms
5. Ripple: 14.53
Winding Currents:
1. RMS: 319.75 A
4. di/dt: 165.83 A/s
Induced Voltages:
5. RMS: 6.5 V
6. Distortion: 1500
8. Crest Factor: 8
48 Slot, 22 Pole
72 Slot, 32 Pole
Stranded Losses:
1. Average: 4.42 W
2. Maximum: 7.80 W
Flux Linkages:
1. RMS: 0.053 Wb
Moving Torque:
6. Rise Time: 9 ms
7. Value: 36.68 Nm
8. Pulsation: 14 Nm,
3.37 ms
10. Ripple: 21.36
Winding Currents:
5. RMS: 29.5 A
8. di/dt: 39.75 A/s
Induced Voltages:
9. RMS: 20 V
10. Distortion: 86
Stranded Losses:
3. Average: 28.3 W
4. Maximum: 46.21 W
Flux Linkages:
3. RMS: 0.0390 Wb
Moving Torque:
2. Value: 19.77 Nm
0.97 ms
5. Ripple: 14.81
Winding Currents:
1. RMS: 12.6 A
4. di/dt: 4.85 A/s
71
Stranded Losses:
1. Average: 3.49 kW
2. Maximum: 4.52 kW
Flux Linkages:
1. RMS: 0.068 Wb
243530 Tetrahedra
Moving Torque:
6. Rise Time: 6 ms
7. Value: 38.6Nm
2.4ms
10. Ripple: 25.15
Winding Currents:
5. RMS = 26 A
8. di/dt: 53.03 A/s
Induced Voltages:
5. RMS: 19 V
6. Distortion: 50
Stranded Losses:
3. Average: 25.9 W
4. Maximum: 47.44 W
Flux Linkages:
3. RMS: 0.060 Wb
89509 Tetrahedra
Moving Torque:
2. Value: 42 Nm
0.20 ms
5. Ripple: 16.44
Winding Currents:
1. RMS = 28.8 A
4. di/dt: 11.91 A/s
Induced Voltages:
13. RMS: 19.5 V
14. Distortion: 67
Stranded Losses:
5. Average: 2.85 W
6. Maximum: 4.91 W
Flux Linkages:
5. RMS: 0.0296 Wb
Induced Voltages:
9. RMS: 18.4 V
10. Distortion: 64
Stranded Losses:
5. Average: 20.64 W
6. Maximum: 34.53 W
Flux Linkages:
5. RMS: 0.0273 Wb
Table 39: 2D and 3D Plot and Filed Observations
7.1. 2D & 3D Result Analysis:

Considering the resulting waveforms of torque, winding currents, induced voltages, stranded
losses and flux linkages. It was observed that 24 Slot and 36 Slot Machines the moving torque for
both 2D and 3D models were in agreement, the winding currents for the 3D model has abnormally
high value of 300 600 A as compared to the 2D model which consequently resulted in high
stranded losses in orders of kW, which is not true or practical, also the induced voltage waveforms
for the 3D model were highly distorted. The flux linkages for both the models were in agreement
with each other. For the 36 Slot and 72 Slot Machines all waveform characteristics were in
complete agreement with each other except some minor fluctuations. The magnitude of waveform
parameters were also in practical limits for 48 and 72 Slot Machines. This flaw in simulation result
could be due to errors in converting a 2D RMxprt design to a Maxwell 3D design.
72
8. Conclusion:
The BLDC Machine was chosen as a motor for a high-performance e-bike. Scientific literature
review and analytical model of the machine led to estimation of rated operating parameters. Four
Models of a 1500 W, 48 V, 380 Rpm, 40 Nm motor were designed and simulated in Maxwell 2D
and 3D. Initial machine analysis in RMxprt module of Maxwell revealed that the Transistor/Diode
Drop along with the type of steel used influenced the efficiency of the machines greatly. It is
advisable to have stator slot fill factors in practical limits and skewed slots to minimize cogging.
2D Analysis results reveal excessive magnetic flux densities in the stator teeth of the 24 Slot and
36 Slot Machines. The torque pulsations and wave form distortion were prominent in 24 and 36
Slot machines as compared to 48 and 72 Slot Machines. Winding currents for all machines had
nominal magnitude and minor harmonics. 3D Plots show densities of 4T and excess in isolated
place at the back of the lamination stack in 48 Slot and 72 Slot motor. Overall we can say that, for
the decided application a higher slot and pole number BLDC machine is preferred. The increase
in weight and dimensions due to high slot number is compensated well by increase in efficiency,
motor constants and decrease in thermal & electrical loading. The 72 Slot, 32 Pole Machine
matches best our desired performance due to its nominal magnetic field densities, lower current
density, lower losses and proximity to rated operating parameters along with accordance with
current similar power machines in the market make it a viable choice.
Parameters
24 S, 16 P
36 S, 16 P 48 S, 22 P 72 S, 22 P
Number of Conductors per Slot:

Length of Stator Core (mm):
Wire Diameter (mm)
Outer Diameter of Stator (mm):
Outer Diameter of Rotor (mm):
Armature Phase Resistance ():
Back-EMF Constant KE (V/rad):
Torque Constant KT (Nm/A):
Stator Slot Fill Factor (%):
Type of Steel:
Total Net Weight (kg):
Air-Gap Flux Density (T):
Stator-Teeth Flux Density (T):
RMS Armature Current (A):
Stator Current Density (A/mm2):
Iron-Core Loss (W):
Armature Copper Loss (W):
Transistor Loss (W):
Diode Loss (W):
Total Loss (W)
Output Power (W)
Input Power
Efficiency (%):
Rated Speed (rpm):
Rated Torque (N.m):
No Load Speed (rpm)
15
50
1.369
180
200
0.030
0.908
1.06
60.32
M100-23P
7.36759
0.927284
3.95
36.23
4.92
0.0045419
69.8671
159.186
11.5828
272.741
1500.21
1772.95
82.20
359
39.92
465.25
12
50
1.369
220
240
0.0253
0.89
0.57
61.44
M100-23P
9.30647
0.92
3.68
32.72
3.70
0.0059985
81.2904
154.496
6.37652
277.608
1500.25
1777.86
84.3853
407.744
35.13
473.53
Table 40: Solution Summary

73
9
50
1.369
240
262
0.025
0.97
1.04
68.72
M100-23P
11.57
0.92
3.1
32.22
3.64
0.0065836
77.0654
152.614
5.51832
264.996
1500.14
1765.14
84.9872
378.866
37.8109
434.62
6
47
1.369
270
290
0.021
1
1.06
53.92
M100-23P
10.4
0.91
3.43
31.57
3.57
0.0117751
64.2301
150.263
4.56598
248.334
1500.1
1748.43
85.7968
375.96
38.1022
422.83
9. Bibliography
[1]
O. Bolton, "Electrical bicycle". Canton, Ohio Patent US 552271 A, 19 September 1895.
[2]
Faulhaber Group, "www.micromo.com," [Online]. Available:

http://static.micromo.com/media/wysiwyg/Technicallibrary/Brushless/Brushless_Application_Advantage_WP.pdf.
[3]
P. T. T.G. Wilson, "D.C. Machine. With Solid State Commutation," AIEE, 1962.
[4]
Pushek Madaan, Cypress Semiconductor, "www.edn.com," 11 February 2013. [Online]. Available:

http://www.edn.com/design/sensors/4406682/Brushless-DC-Motors---Part-I--Construction-andOperating-Principles.
[5]
H. T. W. I. Muhammad Nizam, "Design of Optimal Outer Rotor Brushless DC for Minimum

Cogging Torque," in Joint International Conference on Rural Information & Communication
Technology and Electric-Vehicle Technology (rICT & ICeV-T), Bandung-Bali, Indonesia, 2013.
[6]
Beikimco, "www.beikimco.com," [Online]. Available: http://www.beikimco.com/resourcesdownloads/about-bldc-motors/what-is-a-brushless-DC-motor.
[7]
Honeywell, "www.digikey.com," June 2012. [Online]. Available:

http://www.digikey.com/Web%20Export/Supplier%20Content/HoneywellSC_480/PDF/honeywell
-an-ss-hall-effects.pdf.
[8]
Microchip Technology Inc., "www.microchip.com," 2007. [Online]. Available:

http://ww1.microchip.com/downloads/en/AppNotes/01083a.pdf.
[9]
Atmel Corporation, "www.atmel.com," 2005. [Online]. Available:

http://www.atmel.com/images/doc8012.pdf.
[10] A. Reinap, "Design of Powder Core Motors," Department of Industrial Electrical Engineering and
Automation, Lund University , Lund, Sweden, 2004.
[11] M.-F. H. M. P. L. E. D. A. S. a. V. G. David G. Dorrell, "A Review of the Design Issues and
Techniques for Radial-Flux Brushless Surface and Internal Rare-Earth Permanent-Magnet Motor,"
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, vol. 58, no. 9, pp. 3741 - 3757, 2011.
[12] A. B. Nishtha Shrivastava, "Design of 3-Phase BLDC Motor for Electric Vehicle Application by
Using Finite Element Simulation.," International Journal of Emerging Technology and Advanced
Engineering, vol. IV, no. 1, pp. 140-145, 2014.
[13] P. S. A. v. d. B. Isabelle Hofman, "Influence of Soft-Magnetic Material in a Permanenet Magnet
Synchronous Machine With a Commerical Induction Machine Stator," IEEE Transcations on
Magnetics, Belgium, 2012.
74
[14] N. Abdolamir, "Design a single-phase BLDC Motor and Finite- Element Analysis of Stator Slots
Structure Effects on the Efficiency," International Journal of Electrical, Computer, Energetic,
Electronic and Communication Engineering, pp. 685 - 692, 2011.
[15] Magna Physics Corporation, James R. Hendershot, "Brushless DC Motor Phase, Pole & Slot
Configurations," Hillsboro, Ohio.
[16] ANSYS, "ANSYS MAXWELL," January 2016. [Online]. Available:
http://www.ansys.com/Products/Electronics/ANSYS-Maxwell.
[17] R. Nave, "www.hyperphysics.com," [Online]. Available: http://hyperphysics.phyastr.gsu.edu/hbase/electric/maxeq.html#c1.
[18] Ansoft - ANSYS, "www.ansys.com," Ansoft, 2016. [Online]. Available:
http://www.ansys.com/Products/Electronics/ANSYS-RMxprt.
[19] ANSYS, Inc, "www.scribid.com," June 2015. [Online]. Available:
https://www.scribd.com/doc/129666336/RMxprt-Manual-pdf.
[20] V. P. Buhr Karel, "ANALYSIS OF THE ELECTRIC VEHICLE WITH THE BLDC PM MOTOR
IN THE WHEEL BODY," Prague.
[21] S. T. L. J. H. R. K. T. C. Bo Long, "Energy-Regenerative Braking Control of Electric Vehicles
Using Three-Phase Brushless Direct-Current Motors," energies, vol. 7, pp. 99-114, 2014.
[22] UNEP, "www.unep.org," UNEP, 2000. [Online]. Available:
http://www.unep.org/transport/gfei/autotool/approaches/information/test_cycles.asp#European.
[23] Ansys , "Lecture 6: Meshing and Mesh Operations ANSYS Maxwell V16 Training Manual," 21
May 2013. [Online]. Available: http://ansoftmaxwell.narod.ru/en/Maxwell_v16_L06_Mesh_Operations.pdf.
[24] D. Koeppel, "Flight of the Pigeon," Bicycling (Rodale, Inc.), January 2007.
[25] V. V. H. Adrian Christen, "Analysis of a Six- and Three-Phase Interior Permanentmagnet
Synchronous Machine with Flux Concentration for an Electrical Bike," in International Symposium
on Power Electronics, Electrical Drives, Automation and Motion, Horw-Lucerne, Switzerland,
2014.
75
Appendix 1: 24 Slot, 16 Pole Machine Solution Set:

GENERAL DATA
Rated Output Power (kW):
Rated Voltage (V):
Number of Poles:
Given Rated Speed (rpm):
Frictional Loss (W):
Windage Loss (W):
Rotor Position:
Type of Load:
Type of Circuit:
Lead Angle of Trigger in Elec. Degrees:
Trigger Pulse Width in Elec. Degrees:
One-Transistor Voltage Drop (V):
One-Diode Voltage Drop (V):
Operating Temperature (C):
Maximum Current for CCC (A):
Minimum Current for CCC (A):
STATOR DATA
Number of Stator Slots:
Inner Diameter of Stator (mm):
Type of Stator Slot:
Stator Slot
hs0 (mm):
hs1 (mm):
hs2 (mm):
bs0 (mm):
bs1 (mm):
bs2 (mm):
rs (mm):
Top Tooth Width (mm):
Bottom Tooth Width (mm):
Skew Width (Number of Slots)
Stacking Factor of Stator Core:
Type of Steel:
Designed Wedge Thickness (mm):
Slot Insulation Thickness (mm):
Layer Insulation Thickness (mm):
End Length Adjustment (mm):
Number of Parallel Branches:
1.5
48
16
380
10
20
Outer
Constant Power
Y3
0
120
2
2
75
0
0
24
180
90
4
4
4
30
3
15
7
0.6
6.53136
6.63135
0.5
50
0.95
M100-23P
1
0.5
0.5
2
1
76

Type of Coils:
Average Coil Pitch:
Number of Wires per Conductor:
Wire Diameter (mm):
Wire Wrap Thickness (mm):
Slot Area (mm^2):
Net Slot Area (mm^2):
Limited Slot Fill Factor (%):
Coil Half-Turn Length (mm):
ROTOR DATA
Minimum Air Gap (mm):
Outer Diameter (mm):
Length of Rotor (mm):
Stacking Factor of Iron Core:
Type of Steel:
Polar Arc Radius (mm):
Mechanical Pole Embrace:
Electrical Pole Embrace:
Max. Thickness of Magnet (mm):
Width of Magnet (mm):
Type of Magnet:
Type of Rotor:
Magnetic Shaft:
PERMANENT MAGNET DATA
Residual Flux Density (Tesla):
Coercive Force (kA/m):
Maximum Energy Density (kJ/m^3):
Relative Recoil Permeability:
Demagnetized Flux Density (Tesla):
Recoil Residual Flux Density (Tesla):
Recoil Coercive Force (kA/m):
MATERIAL CONSUMPTION
Armature Copper Density (kg/m^3):
Permanent Magnet Density (kg/m^3):
Armature Core Steel Density (kg/m^3):
15
21
1
6
1.369
0.2
399.178
321.76
75
68.8583
66.786
Rotor Core Steel Density (kg/m^3):

Armature Copper Weight (kg):
Permanent Magnet Weight (kg):
Armature Core Steel Weight (kg):
Rotor Core Steel Weight (kg):
7872
1.88984
0.778336
3.55407
1.14534
1
200
50
0.95
M100-23P
91
0.9
0.884254
4
31.9949
NdFe35
1
No
1.23
890
273.675
1.09981
7.51E-05
1.23
890
8900
7400
7872
77

Armature Core Steel Consumption (kg):
Rotor Core Steel Consumption (kg):
STEADY STATE PARAMETERS
Stator Winding Factor:
D-Axis Reactive Inductance Lad (H):
Q-Axis Reactive Inductance Laq (H):
D-Axis Inductance L1+Lad(H):
Q-Axis Inductance L1+Laq(H):
Armature Leakage Inductance L1 (H):
Zero-Sequence Inductance L0 (H):
Armature Phase Resistance R1 (ohm):
Armature Phase Resistance at 20C (ohm):
7.36759
9.83492
5.57395
D-Axis Time Constant (s):

Q-Axis Time Constant (s):
Ideal Back-EMF Constant KE (Vs/rad):
Start Torque Constant KT (Nm/A):
Rated Torque Constant KT (Nm/A):
NO-LOAD MAGNETIC DATA
Stator-Teeth Flux Density (Tesla):
Stator-Yoke Flux Density (Tesla):
Rotor-Yoke Flux Density (Tesla):
Air-Gap Flux Density (Tesla):
Magnet Flux Density (Tesla):
Stator-Teeth By-Pass Factor:
Stator-Yoke By-Pass Factor:
Rotor-Yoke By-Pass Factor:
Stator-Teeth Ampere Turns (A.T):
Stator-Yoke Ampere Turns (A.T):
Rotor-Yoke Ampere Turns (A.T):
Air-Gap Ampere Turns (A.T):
Magnet Ampere Turns (A.T):
Armature Reactive Ampere Turns at Start Operation (A.T):
Leakage-Flux Factor:
Correction Factor for Magnetic Circuit Length of Stator Yoke:
Correction Factor for Magnetic Circuit Length of Rotor Yoke:
No-Load Speed (rpm):
Cogging Torque (N.m):
FULL-LOAD DATA
Average Input Current (A):
Root-Mean-Square Armature Current (A):
Armature Thermal Load (A^2/mm^3):
0.0053958
0.0053958
0.88399
0.884069
1.01286
0.866025
1.06E-04
1.06E-04
0.0003675
0.0003675
0.0002613
5.29E-05
0.0196915
0.0161978
78
3.68565
2.40341
3.1725
0.927284
0.95876
2.83E-05
9.09E-07
8.50E-07
1.56826
0.246102
0.600627
782.694
-785.051
4257.22
1
0.785552
0.770387
478.439
2.16E-11
36.9364
34.3903
85.2521
Specific Electric Loading (A/mm):

Armature Current Density (A/mm^2):
Frictional and Windage Loss (W):
Iron-Core Loss (W):
Diode Loss (W):
Total Loss (W):
Output Power (W):
Input Power (W):
Efficiency (%):
Rated Speed (rpm):
Rated Torque (N.m):
Locked-Rotor Torque (N.m):
Locked-Rotor Current (A):
WINDING ARRANGEMENT
The 3-phase, 2-layer winding can be arranged in 6 slots as below:
Angle per slot (elec. degrees):
Phase-A axis (elec. degrees):
First slot center (elec. degrees):
TRANSIENT FEA INPUT DATA
For Armature Winding:
Number of Turns:
Parallel Branches:
Terminal Resistance (ohm):
End Leakage Inductance (H):
2D Equivalent Value:
Equivalent Model Depth (mm):
Equivalent Stator Stacking Factor:
Equivalent Rotor Stacking Factor:
Equivalent Br (Tesla):
Equivalent Hc (kA/m):
Estimated Rotor Moment of Inertia (kg m^2):
79
21.8936
3.89393
32.1006
0.0045419
69.8671
159.186
11.5828
272.741
1500.21
1772.95
84.6165
391.121
36.6278
986.927
1116.63
ABCABC
120
60
0
60
1
0.0196915
1.53E-06
50
0.95
0.95
1.23
890
0.0585181
Input DC Current V/s Speed
Efficiency V/s Speed
Ratio of Air-Gap Torque to DC Current V/s Speed
80
Output Power V/s Speed
Output Torque V/s Speed
Induced Coil Voltages at rated Speed
81
Air-Gap Flux Density
Induced Winding Voltages at Rated Speed
Winding Currents under Load
82
Winding Voltages under Load
83

GENERAL DATA
Rated Voltage (V):
Number of Poles:
Windage Loss (W):
Rotor Position:
Type of Load:
Type of Circuit:
STATOR DATA
Stator Slot
hs0 (mm):
hs1 (mm):
hs2 (mm):
bs0 (mm):
bs1 (mm):
bs2 (mm):
rs (mm):
Type of Steel:
1.5
48
16
500
13.1579
45.5606
Outer
Constant Power
Y3
0
120
2
2
75
0
0
36
220
130
4
3
2
30
3
13
8
0.6
5.35039
5.10202
1
50
0.95
M100-23P
0.3
0.5
0.5
5
1
84

12
21
1
6
1.369
0.2
352.929
288.465
75
61.4448
71.502
Type of Coils:
Average Coil Pitch:
Wire Diameter (mm):
Slot Area (mm^2):
ROTOR DATA
Type of Steel:
Type of Magnet:
Type of Rotor:
Magnetic Shaft:
1
240
50
0.95
M100-23P
111
0.95
0.928161
4
41.1704
NdFe35
1
No
1.23
890
273.675
1.09981
0.201572
1.23
890
8900
7400
7872
7872
2.42795
0.99826
4.49998
1.38028
85

9.30647
14.6042

FULL-LOAD DATA
7.47538
75.8034
86
0.616944
9.37E-05
9.37E-05
0.0002248
0.0002248
0.000131
0.0001843
0.0252984
0.0208099
0.0037055
0.0037055
0.892994
0.893053
0.971026
3.80224
2.10836
4.04805
0.922273
0.956058
3.37E-05
9.44E-07
8.09E-07
1.51408
0.322902
0.852621
790.189
-792.874
2808.85
1
0.783171
0.746887
473.536
4.18E-12
37.0386
32.7275

Iron-Core Loss (W):
Diode Loss (W):
Total Loss (W):
Output Power (W):
Input Power (W):
Efficiency (%):
Rated Speed (rpm):
Rated Torque (N.m):
WINDING ARRANGEMENT
Number of Turns:
Parallel Branches:
87
20.4562
3.70565
35.4384
0.0059985
81.2904
154.496
6.37652
277.608
1500.25
1777.86
84.3853
407.744
35.1355
775.947
869.152
AZBCYABXC
80
60
0
72
1
0.0252984
2.23E-06
50
0.95
0.95
1.23
890
0.115407
Ratio of Air-Gap torque to DC Current V/s Speed
88
Induced Coil Voltages at Rated Speed
89
90
91

GENERAL DATA
Rated Voltage (V):
Number of Poles:
Windage Loss (W):
Rotor Position:
Type of Load:
Type of Circuit:
STATOR DATA
Stator Slot
hs0 (mm):
hs1 (mm):
hs2 (mm):
bs0 (mm):
bs1 (mm):
bs2 (mm):
rs (mm):
Type of Steel:
1.5
48
22
380
10
20
Outer
Constant Power
Y3
0
120
2
2
75
0
0
48
240
140
4
2
2
30
3
10
6
0.5
5.19371
5.26096
1
50
0.95
M100-23P
0.3
0.7
0.7
92

Type of Coils:
Average Coil Pitch:
Wire Diameter (mm):
Slot Area (mm^2):
ROTOR DATA
Type of Steel:
Type of Magnet:
Type of Rotor:
Magnetic Shaft:
5
1
9
21
1
6
1.369
0.2
267.176
193.44
75
68.7216
69.9362
1
262
50
0.95
M100-23P
121
0.9
0.88304
4
3.10E+01
NdFe35
1
No
1.23
890
273.675
1.09981
0.376492
1.23
890
8.90E+03
7400
7872
7872
2.37478
1.02941
6.36438
93

FULL-LOAD DATA
94
1.80435
11.5729
17.3413
8.91725
0.630095
5.60E-05
5.60E-05
1.59E-04
0.0001587
0.0001027
0.0001307
0.0247444
0.0203542
0.0022637
0.0022637
0.972909
0.972948
1.04863
3.10027
0.973274
2.54133
0.920478
0.952004
2.70E-05
1.27E-06
8.96E-07
1.28673
0.166551
0.49229
802.471
-804.607
2151.7
1
0.799931
0.782633
434.642
7.81E-12
36.7737
32.2204

Iron-Core Loss (W):
Diode Loss (W):
Total Loss (W):
Output Power (W):
Input Power (W):
Efficiency (%):
Rated Speed (rpm):
Rated Torque (N.m):
WINDING ARRANGEMENT
Number of Turns:
Parallel Branches:
67.3498
18.4609
3.64824
29.7917
0.0065836
77.0654
152.614
5.51832
264.996
1500.14
1765.14
84.9872
378.866
37.8109
864.32
888.611
AZBCYABXYAZXCYZ
BCYABXCAZ
82.5
67.0827
0
72
1
0.0247444
1.56E-06
50
0.95
0.95
1.23
890
0.164846
95
96
97
98
99

GENERAL DATA
Rated Voltage (V):
Number of Poles:
Windage Loss (W):
Rotor Position:
Type of Load:
Type of Circuit:
STATOR DATA
Stator Slot
hs0 (mm):
hs1 (mm):
hs2 (mm):
bs0 (mm):
bs1 (mm):
bs2 (mm):
rs (mm):
Type of Steel:
Type of Coils:
1.5
48
32
330
8.68421
13.0985
Outer
Constant Power
Y3
0
120
2
2
75
72
270
180
4
2.5
1
30
3
8
5.3
0.5
3.47879
3.55905
1
47
0.95
M100-23P
0.2
0.5
0.5
3
1
6
21
100
Average Coil Pitch:

Wire Diameter (mm):
Slot Area (mm^2):
ROTOR DATA
Type of Steel:
Type of Magnet:
Type of Rotor:
Magnetic Shaft:
1
6
1.369
0.2
217.113
164.332
75
53.9295
60.6786

7872
2.06043
1.08565
5.68578
1.57352
10.4054
20.5741
1
290
47
0.95
M100-23P
136
0.9
0.870756
4
2.40E+01
NdFe35
1
No
1.23
890
273.675
1.09981
0.501114
1.23E+00
8.90E+02
8900
7400
7872
101

FULL-LOAD DATA
102
9.60048
0.616944
2.66E-05
2.66E-05
9.47E-05
9.47E-05
6.81E-05
9.50E-05
0.0214689
0.0176599
0.0012389
0.0012389
1.00006
1.00008
1.06643
3.43167
1.03492
2.31132
0.912484
0.945547
3.24E-05
1.24E-06
9.19E-07
1.35
0.145211
0.355407
821.691
-823.293
1673.22
1
0.799752
7.91E-01
422.834
6.21E-12
36.4257
31.5794
57.5081
16.0832
3.57566
29.2626
Iron-Core Loss (W):

Diode Loss (W):
Total Loss (W):
Output Power (W):
Input Power (W):
Efficiency (%):
Rated Speed (rpm):
Rated Torque (N.m):
WINDING ARRANGEMENT
Number of Turns:
Parallel Branches:
103
0.0117751
64.2301
150.263
4.56598
248.334
1500.1
1748.43
85.7968
375.96
38.1022
1024.02
1024.18
AZBCYABXC
80
6.00E+01
0
72
1
0.0214689
6.11E-07
47
0.95
0.95
1.23
890
0.215067
104
105
106
107
Appendix 5: Steel Data:

1. Name: Unisil H M100 23P
2. Manufacturer: Cogent
Maximum specific loss
(W/kg) at 1.7T
Name
M10023P
Typical specific loss

(W/kg) at 1.7T
50Hz
60Hz
50Hz
60Hz
1.00
1.32
0.92
1.19
Polarization at
H=800 A/m 1
50 Hz
Min T / Typical T
1.88/1.91
Core Loss (W/Kg)
B (T) - Core loss (W/Kg)

1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0
0.5
1
Magnetic Field Density (T)
108
1.5
Magnetization Data
Core Loss Data
B (T)
B (T) Core loss (W/Kg) H (A/m)
0.1
0.1
0.009
3.5
0.2
0.2
0.018
5.8
0.3
0.3
0.035
8
0.4
0.4
0.06
9.5
0.5
0.5
0.09
12
0.6
0.6
0.11
14
0.7
0.7
0.15
15
0.8
0.8
0.19
17
0.9
0.9
0.23
18
1
1
0.29
19
1.1
1.1
0.35
20
1.2
1.2
0.4
21
1.3
1.3
0.5
22
1.4
1.4
0.55
24
1.5
1.5
0.65
30
1.6
1.6
0.78
41
1.7
1.7
1
75
1.8
1.8
1.4
200
1.9
1.9
1.7
1000
B (T) - H (A/m)
Current Density (A/m)
1200
1000
800
600
400
200
0
0
0.5
1
Magnetic Field Density (T)
109
1.5

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Czech Technical University in Prague

Faculty of Electrical Engineering

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Prathamesh Mukund Dusane

Date: 2nd June 2016

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Aim & Objective:

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

5.1.3. Rotor Dimensions: ........................................................................................................................ 27

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

1. Background of the BLDC Machine

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 2: A) Radial Flux Motor, B) Axial Flux Motor [10]

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

2. BLDC Machine literature review

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

3. ANSYS Maxwell familiarization

Faradays Law of Induction =

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

3.1. ANSYS RMxprt:

Figure 3: Machine selection interface in RMxprt

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 4: Project Manager Window

Figure 5: Machine Properties Window

Figure 6: Circuit Properties Window

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 7: Lead Angle of Trigger [19]

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 9: Slot Dimensions Window

Figure 10: Slot Model

Figure 12: Whole Coiled (Left) & Half Coiled (Right)

Figure 11: Winding Properties Window

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 14: End/Insulation Tab

Figure 15: Coil End of the Winding [19]

Figure 16: Slot Insulation of the Stator [19]

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 17: Rotor Data Properties Window

Figure 18: Pole Properties Window

Pole Embrace = 0.8

Figure 19: Pole Embrace

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 20: Shaft Properties Window

Figure 21: Analysis Setup Window

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

Figure 22: Stator Winding Performance

Figure 23: Full-Load data Design Sheet

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

4. 1500 W, BLDC Machine Analytical Model

FA - Air resistance/Aerodynamic drag

1. Air Resistance/Aerodynamic Drag

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

4.1. Air Resistance/Aerodynamic Drag:

Nose form factor

Open passenger vehicle

Table 2: Nose Form Factor of Vehicle

1W is the power required by an object of 1Kg to accelerate at 1m/s2 through a distance of 1m in 1

Simulation of a Brushless DC Motor in ANSYS Maxwell 3D

4.2. Rolling Resistance: